NorthStar 49162 User manual

SAVE THESE INSTRUCTIONS
163cc Reversible Plate Compactor
Owner’s Manual
WARNING: Read and understand all instructions, warnings, and cautions before using this
product. Failure to follow the instructions, warnings, and cautions may result in serious personal
injury and/or property damage.
Item #49162

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Thank you very much for choosing a Northstar product!
For future reference, please complete the owner’s record below:
Serial Number/Lot Date Code: ________________________________
Purchase Date: ____________________________________________
Save the receipt, warranty, and this manual.
This plate compactor is designed for certain applications only. Northern
Tool and Equipment cannot be responsible for issues arising from modi-
fication or use of this product in an application for which it was not de-
signed. We strongly recommend that this product not be modified and/or
used for any application other than that for which it was designed.
For technical questions, please call 1-800-222-5381.

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Table of Contents
Intended Use..........................................................................................................................................4
Technical Specifications......................................................................................................................5
Important Safety Information...............................................................................................................5
Specific Operation Warnings...............................................................................................................9
Main Parts of Plate Compactor..........................................................................................................10
Before Each Use..................................................................................................................................11
Operating Instructions........................................................................................................................12
Operation Principle.........................................................................................................................12
Engine Speeds and Machine Performance....................................................................................13
Operating on a Slope......................................................................................................................13
Fuel Recommendations..................................................................................................................13
Operating the Compactor ...............................................................................................................13
After Each Use.....................................................................................................................................15
Maintenance ........................................................................................................................................16
Changing the V-belt ............................................................................................................................17
Parts Diagram......................................................................................................................................18
Compactor Assembly .....................................................................................................................18
Vibrator Plate..................................................................................................................................20
Handle Bar......................................................................................................................................22
Engine Base Plate..........................................................................................................................24
Troubleshooting..................................................................................................................................25
Replacement Parts..............................................................................................................................26
Limited Warranty.................................................................................................................................27

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Intended Use
The reversible plate compactor produces low amplitude high frequency vibrations, designed to com-
pact granular soil, cable and water trenches, marginal strips as well as all those compaction jobs for
which the use of large machines is not convenient. It is equipped with a water tank is used for com-
paction of asphalt pavement finishing and flatwork.
The compactor is not designed or intended for any use other than stated in the owner’s manual.
The compactor is intended for use in confined areas and areas next to structures such as walls,
curbs, and foundations. The plate is not recommended for compacting cohesive soils with a heavy
clay content. For cohesive soil, use a vibratory rammer or sheeps-foot roller.
Power Source. The plate compactor is powered by a gasoline engine.
Supplies Required. Normal operation will require you to supply:
Gasoline
Engine oil
Personal Protection Equipment
See “Specifications” section of this manual or Engine Manual for more detail.
Site Location. Intended for outdoor use only.

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Technical Specifications
Compactor
Weight
202.8 ~ 209.4 lbs. (92 ~ 95 Kg)
Centrifugal Force
4046 lbs. (1835 Kgf)
Vibration Frequency
100 Hz (6000 VPM)
Travel Speed (depending on soil)
82 ft./min (25 m/min)
Grade Ability
20%
Compacted Area (depending on soil)
6781.2 ft2/hr (630 m2/hr)
Power Take-Off
Centrifugal Clutch & V-Belt
Engine
Engine Maker
HONDA
Engine Model
GX 160 / 163cc
Output Power(max)
5.5 Hp. (4.0 Kw)
Spark Plug
BPR6ES(NGK)
W20EPR-U(DENSO)
Spark Plug Gap
0.028-0.031 in. (0.7-0.8 mm)
Engine Speed - Full Load
3,600±100 RPM
Engine Speed - Idle
1,400±100 RPM
Air Cleaner Type
Dual Element
Engine Oil Type
SAE 10W-30
Engine Oil Capacity
20 oz. (600 ml)
Fuel Type
Unleaded Gasoline
Fuel Tank Capacity
3.8 qt. (3.6 l)
Important Safety Information
The warnings, cautions, and instructions in this manual cannot cover all possible conditions or
situations that could occur. Exercise common sense and caution when using this tool. Always be
aware of the environment and ensure that the tool is used in a safe and responsible manner.
DO NOT allow persons to assemble or operate this product until they have read this manual and
have developed a thorough understanding of how the product works.
Use the right tool for the job. DO NOT attempt to force small equipment to do the work of larger
industrial equipment. There are certain applications for which this equipment was designed. It will
do the job better and more safely at the capacity for which it was intended. DO NOT use this
equipment for a purpose for which it was not intended.
Industrial or commercial applications must follow OSHA requirements.

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Some dust created by power sanding, sawing, grinding, drilling, and other construction activities
contains chemicals known to the State of California to cause cancer, birth defects, or other repro-
ductive harm. Some examples of these chemicals are:
-lead from lead-based paints,
-crystalline silica from bricks and cement and other masonry products, and
-arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To re-
duce your exposure to these chemicals: work in a well-ventilated area, and work with approved
safety equipment, such as dust masks that are specially designed to filter out microscopic parti-
cles.
Handling the power cord on corded products may expose you to lead, a chemical known to the
State of California to cause cancer and birth defects or other reproductive harm. Wash your
hands after handling.
WORK AREA SAFETY
Inspect the work area before each use. Keep the work area clean, dry, free of clutter, and well lit.
Cluttered, wet, or dark work areas can result in injury.
Do not use the tool where there is a risk of causing a fire or an explosion; e.g., in the presence of
flammable liquids, gases, or dust. The tool can create sparks, which may ignite the flammable liq-
uids, gases, or dust.
Do not allow the tool to come into contact with an electrical source. The tool is not insulated and
contact will cause electrical shock.
Keep children and bystanders away from the work area while operating the tool. Do not allow
children to handle the tool.
Be aware of all power lines, electrical circuits, water pipes, and other mechanical hazards in your
work area. Some of these hazards may be hidden from your view and may cause personal injury
and/or property damage if contacted.

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PERSONAL SAFETY
Stay alert, watch what you are doing, and use common sense when operating the tool. Do not
use the tool while you are tired or under the influence of drugs, alcohol, or medication.
Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair, clothing
and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving
parts. Air vents on the tool often cover moving parts and should be avoided.
Use safety apparel and equipment. Use ANSI Z87.1-approved safety goggles or safety glasses
with side shields, or when needed, a face shield. Use a dust mask in dusty work conditions. Also
use non-skid safety shoes, hardhat, gloves, dust collection systems, and hearing protection when
appropriate. This applies to all persons in the work area.
Do not overreach. Keep proper footing and balance at all times.
Remove keys or wrenches before connecting the tool to the power supply or turning on the tool. A
wrench or key that is left attached to a rotating part of the tool may cause personal injury.
Secure the work with clamps or a vise instead of your hand when practical. This safety precaution
allows for proper tool operation using both hands.
No smoking, matches, or open flames around the machine. Fuel is flammable.
Do not touch hot surfaces.
Equipment can tip over when moving, causing injury.
Persons not operating should be at least 10 feet away while equipment is in use.
Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use
indoors.
Do not operate without guards in place.

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COMPACTOR USE AND CARE
Do not force the product. Products do a better and safer job when used in the manner for which
they are designed. Plan your work, and use the correct product for the job.
Check for damaged parts before each use. Carefully check that the product will operate properly
and perform its intended function. Replace damaged or worn parts immediately. Never operate
the product with a damaged part.
Disconnect the power supply from the tool and place the power switch in the locked or off position
before making any adjustments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally.
Store the product when it is not in use. Store it in a dry, secure place out of the reach of children.
Inspect the product for good working condition prior to storage and before re-use.
Use only accessories that are recommended by the manufacturer for use with your product. Ac-
cessories that may be suitable for one product may create a risk of injury when used with another
product.
Keep guards in place and in working order. Never operate the product without the guards in
place.
Do not leave the product running unattended.
Shut off the fuel valve when the engine is not in use.
Only use the recommended fuel to avoid damaging the equipment.
Oil does not come with the machine. Add oil to engine before the first use.
Check oil levels before operating the machine.
DO NOT refuel the engine while it is still hot. Fuel is flammable.
DO NOT service engine while it is still hot.

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Specific Operation Warnings
To avoid fatal accident
Stop the engine before refueling and be careful not to spill fuel. Spilled fuel may ignite.
Do not refuel the engine near flammable objects to avoid fire.
Do not run the engine in enclosed areas to prevent carbon monoxide poisoning.
To protect the operator
When fatigued from operation, stop the machine and take break.
Hearing protection is required as this machine creates a noise emission while 1 m (3 feet) away
from the equipment.
To avoid injury or damage
The compactor is only to be operated by authorized persons who:
-are at least 18 years of age.
-are physically and mentally able to operate the plate compactor.
-are properly trained in the operation and the maintenance of the compactor by the owner or
its authorized representative.
-are assessed to be able to carry out their duties reliably.
Do not operate the compactor when any condition endangers the safety of the operator. Correct
the condition before operating the compactor.
Do not operate the compactor while under the influence of medication or alcohol.
The operator must monitor the immediate area all the times. Do not operate the compactor if a
person is in the immediate area because cracked and bounced rock may cause injury. Also
monitor other objects within 20m in case of lighting.
The compactor can only be operated under adequately stable conditions.
The operator must turn off the compactor completely as described in this manual before leaving
the operating position. Also, the compactor must be secured against unauthorized use.
The engine must be turned off and secured against re-starting by pulling out the spark plug before
maintenance and servicing.
The compactor has to be inspected by an authorized service technician on a regular basis (at
least once a year). The compactor generates mechanical heat so do not touch the engine, muf-
fler or other parts during the operation, which may cause a burn. Please wait until the compactor
cools down before inspecting components.
The operator must be fully equipped with safety equipment including a helmet, safety gloves,
safety shoes, safety glasses, a mask, and hearing protection before operating the compactor.
Do not insert a hand or finger between the pulley cover and engine during operation as it will
break the hand or finger.
Sprinkle the water on the working area to avoid dust before operating but NEVER operate the
compactor if the working area is too wet because it may damage the life cycle of the product.
Lift the plate compactor by a proper lifting crane when moving it on and off a truck. Lifting the
compactor by hand may cause personal injury due to its heavy weight.
Securely fasten the compactor for transportation. Insecure fastening of the compactor may cause
damage or injury during transportation.
Do not transport the plate compactor by motor vehicle with fuel in its fuel tank.
Note: Refer to the instruction manual of the engine if there is a problem or a question about it before
or during its operation.

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Main Parts of Plate Compactor
01
Handle
02
Handle Bar
03
Hydraulic Oil Refill Bolt
04
Frame
05
Engine Air Filter
06
Engine Fuel Tank
07
Accelerator lever
08
Hand Pump Piston
09
Engine Base Plate
10
Vibrator Plate
11
Hydraulic Hose
12
Isolated Rubber
13
Engine Muffler
14
Pulley Cover
15
Belt Cover
16
Handle Position Grip

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Before Each Use
Engine
Recommended Fuel
The compactor engine requires fresh, clean, regular, unleaded gasoline. Fuel containing wa-
ter or dirt will damage the fuel system. Consult to engine owner’s manual for complete fuel
specifications
DANGER: Adding fuel to the tank should be done only when the engine is stopped and has had an
opportunity to cool down to avoid a risk of an explosion or fire from a fuel spill. In the event of a fuel
spill, DO NOT attempt to start the engine until the fuel residue has been completely wiped up, and the
area surrounding the engine is dry.
Before starting
Read and understand the safety and operating instruction manual of the engine.
Check:
- Oil level in engine.
- Fuel level.
- Condition of air cleaner.
- Tightness of external fasteners.
- Condition of fuel lines.
Compactor
Check all the bolts, nuts and belts and tighten any if necessary.
Check the general condition of the compactor and its components and clean any foreign material
(dirt, fragments, etc.) from the compactor that may be thrown off and cause injury.

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Operating Instructions
Operation Principle
Vibrating for ground compacting is accomplished occurred by a vibrator (A) that is installed on the
bottom plate (B) for tamping. There are two shafts in the vibrator for forward and reverse. One shaft
has two centrifugal vibrators. One of these two shafts receives hydraulic force and changes the angle
of the centrifugal vibrator. It makes the compactor move forward and reverse,
The air-cooled 4-stroke engine engine (C) is attached to the engine plate which interacts with the vi-
brator. Torque is delivered through the V - belt (E) that connects the Pulley (D) and the centrifugal
clutch that is attached to the engine.
When the engine operates at low speed, the centrifugal clutch cuts off power to the vibrator. The
speed of the engine is changes by the throttle control lever on the left-side of the handle (A14 in the
parts list).
Four shock absorbers (F) are between the engine plate (A24) and the vibrator plate (A01). This de-
creases the system vibration delivered with the engine plate.

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Engine Speeds and Machine Performance
The engine speed influences to the centrifugal force produced by the vibrator and therefore the vibra-
tion produced. A fast engine speed results in a strong centrifugal force. A slow engine speed greatly
reduces the centrifugal force.
Operating on a Slope
When compacting on a slope, it is easiest to operate the equipment from the top to the bottom of the
slope.
Never stand on the downslope side of the compactor, whether operating from top to bottom of a slope
or sideways on a slope. Do not operate the compactor on a slope of more than maximum of 20%.
On a steeper slope, the engine will dribble oil and can break down.
Fuel Recommendations
Refuel the engine with fresh, clean, regular grade unleaded gasoline. Gasoline that contains water or
dust causes problems in the engine. Refer to the engine owner’s manual fuel specifications.
Operating the Compactor
Operate the engine at full speed so that the compactor can compact properly at normal speed. When
going uphill, the operator may have to push a little to move the compactor forward. When going
downhill, the operator may decrease the speed to adjust to the situation. Compact the soil 3-4 times
according to the material.
A certain amount of moisture in the soil is needed, but excessive moisture disturbs compacting: soil
molecules may clump together. If the soil is very wet, dry it out before compacting.
If soil is dry enough to create dust while compacting, sprinkle some water on the ground to improve
compatibility. Also, this increases the life of the air filter.
Read all the safety information in this manual before operating the compactor.
Do not use the compactor on wet concrete as it is not designed for this purpose.
1) Move the throttle lever to fast position.
Setting the throttle lever to fast produces the proper engine speed and the centrifugal clutch grabs
the engine pulley which transmits power to the vibrator.

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2) To drive the compactor forward, push the travel lever to the forward position (see below).
3) To drive the compactor backward, pull the lever to the reverse position.
Do not move the travel lever with excessive force when engine is turn-off. The lever should move easil
y when the engine is started and the compactor is operating normally. If the lever does not move easi
ly, see the troubleshooting section for the solution.
NOTE: If the compactor does not move in reverse, even when the travel lever is put in reverse, set
the engine throttle lever to low, and repeat moving the travel lever between forward and reverse 15-20
times. When resistance in the lever is felt, move the throttle lever to the fast position and operate the
compactor.
4) Grip the handle firmly as the compactor moves.
5) While compacting, look for debris that might damage the compactor or cause bodily harm.
6) Reduce travel speed when compacting clay so the compactor will not bounce off the ground if cla
y builds up underneath the compactor.
To correct this situation:
- (With the compactor turned off) check under the compactor to determine whether clay or
other material has become stuck to the vibrator plate. If so, clean the plate/mechanism with w
ater and remove the material.
- Remember that the compactor cannot do effective work on clay or very moist soil.
- If the soil is very moist, dry it to a suitable level or perform compaction twice.

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After Each Use
Remove foreign substances such as soil, stone or dirt from compactor and engine.
Clean the engine cylinder cooling fins.
Clean or replace the air filter.
Check the general condition of the compactor.
Storage
In case of storing the plate compactor for a long period of time (for more than 30 days):
Drain the fuel tank completely.
Run the engine until the fuel in the fuel in the carburetor is completely consumed.
Drain the engine oil and follow procedures described in engine manual for engine storage.
Cover the compactor completely with a dry cloth for storage.
Store the compactor in a clean, dry place.

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Maintenance
Check that the plate compactor engine is turned off and cooled before attempting any maintenance,
cleaning, or inspection. Performing maintenance on an operating compactor can cause injury.
Maintain the compactor by adopting a program of conscientious repair and maintenance in accord-
ance with the following recommended procedures. Also refer to the engine manufacturer’s instruction
manual for additional information about engine maintenance. The following chart is based on a normal
operation schedule.
Maintenance Interval
Maintenance Point
Daily before operating
Check the fuel level.
Check the engine oil level.
Inspect the fuel lines.
Inspect the air filter and replace it if needed.
Check and tighten the external hardware.
After the first 20 operating hours
Check and adjust the drive belt.
Change the engine oil.
After the first 50 operating hours or
every week
Check and adjust the drive belt.
Clean the air cleaner element.
Change the engine oil.
Check and clean the spark plug.
After the first 100 operating hours or
every month
Clean the fuel strainer.
After the first 300 operating hours or
every year
Check and adjust the valve clearance.
Clean the cylinder head.
Change the lubrication oil (SHELL OMALA #100 OR SAE
10W/30, 150CC)

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Changing the V-belt
Check that the plate compactor engine is turned off and cool before attempting to change the V-belt.
Changing the V-belt while the compactor is still operating may cause injury.
1. Loose the four flange bolts (02) to remove the belt cover (01).
2. Loose the three socket head bolts (04) to remove the pulley cover (03).
3. Remove the belt.
4. Prepare a new belt (D06 in the parts list).
5. When fitting the belt, fit it to the smaller pulley first, then the bigger pulley.
6. With the belt installed, check whether the distance of A (below) is 3/8”by pushing in on the belt.
7. Fasten the belt cover (01) with the flange bolts (02) and tighten the bolts.
8. Fasten the pulley cover (03) with the socket head bolts (04) and tighten the bolts.

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Parts Diagram
Compactor Assembly

Page 19 of 28
Compactor Assembly
Ref.
Part No.
Description
Qty
Remark
A01
PM040-000
Vibrator Plate Assembly
1
JPC-940R
A02
PA130-002
Shock Absorber
1
A03
QWS-PM10
Plain Washer
1
M10
A04
QNT-CM10
Cap Nut
1
M10
A05
PL070-000B
Handle Bar
1
A06
QWS-PM12
Plain Washer
4
M12(10.9T)
A07
QWS-SM12
Spring Washer
4
M12(10.9T)
A08
QBL-HM12X35
Bolt
4
M12x35L(10.9T)
A09
QWS-CP14
Cupper Washer
1
M14
A10
PL080-007
Oil Cap Bolt
1
A11
PL060-000
Travel Lever
1
A12
QWS-SM8
Spring Washer
2
M8(10.9T)
A13
QBL-HM8X20
Bolt
2
M8x20L
A14
QTL-02
Throttle Lever
1
Magura
A15
QBL-FHM6X10
Flat Head Bolt
2
M6x10L
A16
QTC-S1300
Throttle Cable
1
1300L
A17
GX160-S
Engine
1
S type
A18
QNT-FM8
Flange Nut
4
M8
A19
QNT-M8
Nut
4
M8
A20
PL030-000
Frame
1
A21
QWS-PM10
Plain Washer
4
M10(10.9T)
A22
QWS-SM10
Spring Washer
4
M10(10.9T)
A23
QBL-HM10X35
Bolt
4
M10x35L
A24
PL020-000B
Engine Base Plate Assembly
1
A25
PL020-002
Engine Mount Bolt
2
A26
QWS-PM10
Plain Washer
4
M10 Ø30
A27
QNT-NM10
Nylon Nut
4
M10
A28
QBL-BHCM6*15
S, Button Head Cap Bolt
1
M6*15
A29
QNT-M6
Nut
1
M6

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Vibrator Plate